Systems and methods for rotary tensioning of fibrous preforms

Abstract

A shape forming tool for pre-carbonization compression of a fibrous preform is provided, comprising a female forming tool, a first plug, a second plug, and a wedge, each configured to be received by a die recess of the female forming tool. A first tapered surface of the wedge is configured to engage the first plug and the second tapered surface of the wedge is configured to engage the second plug. In response to the first tapered surface of the wedge engaging the first plug and the second tapered surface of the wedge engaging the second plug, the first plug and the second plug, respectively, are configured to move laterally towards opposing sides of the female forming tool and/or vertically toward a bottom side of the female forming tool to compress the fibrous preform into a shaped body.

1 . A method for forming a fibrous preform, comprising:
 disposing the fibrous preform over a forming tool;   coupling a first side of the fibrous preform to a first rotary tensioner;   moving the fibrous preform to conform to the forming tool;   moving the first side of the fibrous preform with respect to the forming tool in response to moving the fibrous preform to conform to the forming tool; and   applying a first tension to the fibrous preform via the first rotary tensioner as the fibrous preform is moved to conform to the forming tool.   
     
     
         2 . The method of  claim 1 , further comprising:
 coupling a second side of the fibrous preform to a second rotary tensioner;   moving the second side of the fibrous preform with respect to the forming tool in response to moving the fibrous preform to conform to the forming tool; and   applying a second tension to the fibrous preform via the second rotary tensioner as the fibrous preform is moved to conform to the forming tool.   
     
     
         3 . The method of  claim 1 , further comprising clamping the first side of the fibrous preform with a first clamp, wherein the first rotary tensioner applies the first tension to the fibrous preform via the first clamp. 
     
     
         4 . The method of  claim 2 , further comprising clamping the second side of the fibrous preform with a second clamp, wherein the second rotary tensioner applies the second tension to the fibrous preform via the second clamp. 
     
     
         5 . The method of  claim 1 , further comprising rotating the first rotary tensioner in response to the first side of the fibrous preform moving with respect to the forming tool. 
     
     
         6 . The method of  claim 1 , wherein moving the fibrous preform to conform to the forming tool comprises pushing the fibrous preform at least partially into a die recess of the forming tool. 
     
     
         7 . The method of  claim 1 , further comprising varying the first tension with the first rotary tensioner, wherein the first rotary tensioner comprises a rotary actuator. 
     
     
         8 . The method of  claim 1 , wherein the first tension is a constant tension, and the first rotary tensioner comprises a constant tension pulley. 
     
     
         9 . The method of  claim 1 , wherein disposing the fibrous preform over the forming tool comprises placing the fibrous preform onto a first preform support coupled to a first side of the forming tool and a second preform support coupled to a second side of the forming tool. 
     
     
         10 . The method of  claim 1 , further comprising reacting the first tension through a frame separate from the forming tool. 
     
     
         11 . The method of  claim 1 , further comprising reacting the first tension through the forming tool. 
     
     
         12 . A system for shape forming a fibrous preform, comprising:
 a forming tool;   a first support frame disposed at a first side of the forming tool;   a second support frame disposed at a second side of the forming tool;   a first rotary tensioner slidably coupled to the first support frame, whereby a position of the first rotary tensioner with respect to the forming tool is adjustable in a first dimension; and   a second rotary tensioner coupled to the second support frame, whereby a position of the second rotary tensioner with respect to the forming tool is adjustable in the first dimension.   
     
     
         13 . The system of  claim 12 , wherein the forming tool comprises a female forming tool comprising a die recess, wherein the first support frame is disposed at a first side of the female forming tool, and wherein the second support frame is disposed at a second side of the female forming tool. 
     
     
         14 . The system of  claim 13 , wherein the female forming tool extends longitudinally along a longitudinal centerline of the female forming tool between and to a first end of the female forming tool and a second end of the female forming tool, and wherein the female forming tool extends laterally between and to the first side of the female forming tool and the second side of the female forming tool. 
     
     
         15 . The system of  claim 14 , wherein a first sidewall portion of the female forming tool extends vertically between and to a bottom side of the female forming tool and a top side of the female forming tool, and whereby the position of the first rotary tensioner is adjustable in the first dimension with respect to the first sidewall portion of the female forming tool. 
     
     
         16 . The system of  claim 15 , wherein a second sidewall portion of the female forming tool extends vertically between and to the bottom side of the female forming tool and the top side of the female forming tool, and whereby the position of the second rotary tensioner is adjustable in the first dimension with respect to the second sidewall portion of the female forming tool. 
     
     
         17 . The system of  claim 16 , further comprising a third rotary tensioner slidably coupled to the first support frame, whereby a position of the third rotary tensioner with respect to the first sidewall portion of the female forming tool is adjustable in the first dimension 
     
     
         18 . The system of  claim 17 , further comprising a fourth rotary tensioner slidably coupled to the second support frame, whereby a position of the fourth rotary tensioner with respect to the second sidewall portion of the female forming tool is adjustable in the first dimension. 
     
     
         19 . The system of  claim 18 , further comprising a first clamp configured to be coupled to the first rotary tensioner and the third rotary tensioner, wherein the first clamp is moveable with respect to the female forming tool and wherein the first clamp extends from the first end of the female forming tool to the second end of the female forming tool. 
     
     
         20 . The system of  claim 19 , further comprising a second clamp configured to be coupled to the second rotary tensioner and the fourth rotary tensioner, wherein the second clamp is moveable with respect to the female forming tool and wherein the second clamp extends from the first end of the female forming tool to the second end of the female forming tool.